HIMA HIMatrix User manual

HIMatrix
Safety-Related Controller
AO 8 01 Manual
HIMA Paul Hildebrandt GmbH + Co KG
Industrial Automation
Rev. 2.00 HI 800 197 E

HI 800 197 E Rev. 2.00 (1334)
All HIMA products mentioned in this manual are protected by the HIMA trade-mark. Unless noted otherwise,
this also applies to other manufacturers and their respective products referred to herein.
HIMax®, HIMatrix®, SILworX®, XMR®and FlexSILon®are registered trademarks of HIMA Paul Hildebrandt
GmbH + Co KG.
All of the instructions and technical specifications in this manual have been written with great care and
effective quality assurance measures have been implemented to ensure their validity. For questions, please
contact HIMA directly. HIMA appreciates any suggestion on which information should be included in the
manual.
Equipment subject to change without notice. HIMA also reserves the right to modify the written material
without prior notice.
For further information, refer to the HIMA DVD and our website at http://www.hima.de and
http://www.hima.com.
© Copyright 2013, HIMA Paul Hildebrandt GmbH + Co KG
All rights reserved
Contact
HIMA contact details:
HIMA Paul Hildebrandt GmbH + Co KG
P.O. Box 1261
68777 Brühl, Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Type of change
Revision
index
Revisions
technical editorial
1.00 Added: Configuration with SILworX X X
2.00 Added: SIL 4 certified according to EN 50126, EN 50128 and
EN 50129, Chapter 4.1.3
X X

AO 8 01 Table of Contents
HI 800 197 E Rev. 2.00 Page 3 of 38
Table of Contents
1Introduction 5
1.1 Structure and Use of this Manual 5
1.2 Target Audience 6
1.3 Formatting Conventions 7
1.3.1 Safety Notes 7
1.3.2 Operating Tips 8
2Safety 9
2.1 Intended Use 9
2.1.1 Environmental Requirements 9
2.1.2 ESD Protective Measures 9
2.2 Residual Risk 10
2.3 Safety Precautions 10
2.4 Emergency Information 10
3Product Description 11
3.1 Safety Function 11
3.1.1 Safety-Related Analog Outputs 11
3.1.1.1 Switch Positions 11
3.1.1.2 Analog Output Values 12
3.1.1.3 Reaction in the Event of a Fault 12
3.1.1.4 Worst Case Reaction Time 12
3.2 Equipment, Scope of Delivery 13
3.3 Type Label 13
3.4 Structure 14
3.4.1 Block Diagram 14
3.4.2 Front View 15
3.4.3 Status Indicators 16
3.5 Product Data 17
4Start-up 18
4.1 Installation and Mounting 18
4.1.1 Mounting and Removing the Modules 18
4.1.2 Connecting the Analog Outputs 19
4.1.3 Cable Plugs 19
4.1.4 Mounting the AO 8 01 in Zone 2 20
4.2 Configuration 21
4.2.1 Module Slots 21
4.3 Configuration with SILworX 22
4.3.1 Parameters and Error Codes for the Output 22
4.3.2 Analog Outputs 22
4.3.2.1 Tab: Module 22
4.3.2.2 Tab: AO 8: Channels 23

Table of Contents AO 8 01
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4.4 Configuration with ELOP II Factory 24
4.4.1 Configuring the Outputs 24
4.4.2 Signals and Error Codes for the Output 24
4.4.3 Analog Outputs 25
5Operation 27
5.1 Handling 27
5.2 Diagnosis 27
6Maintenance 28
6.1 Faults 28
6.2 Maintenance Measures 28
6.2.1 Loading the Operating System 28
6.2.2 Proof Test 28
7Decommissioning 29
8Transport 30
9Disposal 31
Appendix 33
Glossary 33
Index of Figures 34
Index of Tables 35
Index 36

AO 8 01 1 Introduction
HI 800 197 E Rev. 2.00 Page 5 of 38
1 Introduction
This manual describes the technical characteristics of the module and its use. It provides
information on how to install, start up and configure the module.
1.1 Structure and Use of this Manual
The content of this manual is part of the hardware description of the HIMatrix programmable
electronic system.
This manual is organized in the following main chapters:
Introduction
Safety
Product Description
Start-up
Operation
Maintenance
Decommissioning
Transport
Disposal
The HIMatrix F60 is available for the programming tools SILworX and ELOP II Factory. Which
programming tool can be used, depends on the processor operating system of the HIMatrix
F60, refer to the following table:
Programming tool Processor operating system Communication operating system
SILworX CPU OS V7 and higher COM OS V12 and higher
ELOP II Factory CPU OS up to V6.x COM OS up to V11.x
Table 1: Programming Tools for HIMatrix F60
In the manual, the differences are specified by using:
Separated chapters
Tables differentiating among the versions
iProjects created with ELOP II Factory cannot be edited with SILworX, and vice versa!
iThe manual usually refers to the plug-in cards of the modular controller F60 as modules.
Modules is also the term used in SILworX.

1 Introduction AO 8 01
Page 6 of 38 HI 800 197 E Rev. 2.00
Additionally, the following documents must be taken into account:
Name Content Document number
HIMatrix System Manual
Compact Systems
Hardware description of the HIMatrix
compact systems
HI 800 141 E
HIMatrix System Manual
Modular System F60
Hardware description of the HIMatrix
modular system
HI 800 191 E
HIMatrix Safety Manual Safety functions of the HIMatrix system HI 800 023 E
HIMatrix Safety Manual for
Railway Applications
Safety functions of the HIMatrix system
using the HIMatrix in railway
applications
HI 800 437 E
SILworX Online Help Instructions on how to use SILworX -
ELOP II Factory
Online Help
Instructions on how to use ELOP II
Factory, Ethernet IP protocol
-
SILworX First Steps Introduction to SILworX using the
HIMax system as an example
HI 801 103 E
ELOP II Factory First Steps Introduction to ELOP II Factory HI 800 006 E
Table 2: Additional Relevant Documents
The latest manuals can be downloaded from the HIMA website at www.hima.com. The revision
index on the footer can be used to compare the current version of existing manuals with the
Internet edition.
1.2 Target Audience
This document addresses system planners, configuration engineers, programmers of
automation devices and personnel authorized to implement, operate and maintain the modules
and systems. Specialized knowledge of safety-related automation systems is required.

AO 8 01 1 Introduction
HI 800 197 E Rev. 2.00 Page 7 of 38
1.3 Formatting Conventions
To ensure improved readability and comprehensibility, the following fonts are used in this
document:
Bold To highlight important parts.
Names of buttons, menu functions and tabs that can be clicked and used
in the programming tool.
Italics For parameters and system variables
Courier Literal user inputs
RUN Operating state are designated by capitals
Chapter 1.2.3 Cross references are hyperlinks even though they are not particularly
marked. When the cursor hovers over a hyperlink, it changes its shape.
Click the hyperlink to jump to the corresponding position.
Safety notes and operating tips are particularly marked.
1.3.1 Safety Notes
The safety notes are represented as described below.
These notes must absolutely be observed to reduce the risk to a minimum. The content is
structured as follows:
Signal word: warning, caution, notice
Type and source of risk
Consequences arising from non-observance
Risk prevention
The signal words have the following meanings:
Warning indicates hazardous situation which, if not avoided, could result in death or serious
injury.
Caution indicates hazardous situation which, if not avoided, could result in minor or modest
injury.
Notice indicates a hazardous situation which, if not avoided, could result in property damage.
NOTE
Type and source of damage!
Damage prevention
SIGNAL WORD
Type and source of risk!
Consequences arising from non-observance
Risk prevention

1 Introduction AO 8 01
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1.3.2 Operating Tips
Additional information is structured as presented in the following example:
iThe text corresponding to the additional information is located here.
Useful tips and tricks appear as follows:
TIP The tip text is located here.

AO 8 01 2 Safety
HI 800 197 E Rev. 2.00 Page 9 of 38
2 Safety
All safety information, notes and instructions specified in this document must be strictly
observed. The product may only be used if all guidelines and safety instructions are adhered to.
This product is operated with SELV or PELV. No imminent risk results from the product itself.
The use in Ex-zone is permitted if additional measures are taken.
2.1 Intended Use
HIMatrix components are designed for assembling safety-related controller systems.
When using the components in the HIMatrix system, comply with the following general
requirements.
2.1.1 Environmental Requirements
Requirement type Range of values 1)
Protection class Protection class III in accordance with IEC/EN 61131-2
Ambient temperature 0...+60 °C
Storage temperature -40...+85 °C
Pollution Pollution degree II in accordance with IEC/EN 61131-2
Altitude < 2000 m
Housing Standard: IP20
Supply voltage 24 VDC
1) The values specified in the technical data apply and are decisive for devices with extended
environmental requirements.
Table 3: Environmental Requirements
Exposing the HIMatrix system to environmental conditions other than those specified in this
manual can cause the HIMatrix system to malfunction.
2.1.2 ESD Protective Measures
Only personnel with knowledge of ESD protective measures may modify or extend the system
or replace devices.
NOTE
Device damage due to electrostatic discharge!
When performing the work, make sure that the workspace is free of static, and wear
an ESD wrist strap.
If not used, ensure that the device is protected from electrostatic discharge, e.g., by
storing it in its packaging.

2 Safety AO 8 01
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2.2 Residual Risk
No imminent risk results from a HIMatrix system itself.
Residual risk may result from:
Faults related to engineering
Faults related to the user program
Faults related to the wiring
2.3 Safety Precautions
Observe all local safety requirements and use the protective equipment required on site.
2.4 Emergency Information
A HIMatrix system is a part of the safety equipment of a site. If a device or a module fails, the
system enters the safe state.
In case of emergency, no action that may prevent the HIMatrix systems from operating safely is
permitted.

AO 8 01 3 Product Description
HI 800 197 E Rev. 2.00 Page 11 of 38
3 Product Description
The AO 8 01 is a module for the modular F60 HIMatrix system.
The module can be inserted in the F60 subrack's slot 3...8. Slots 1 and 2 are reserved for the
power supply module and central module, respectively.
The safety-related analog AO 8 01 system has 8 outputs with a 12-bit resolution. Each group of
8 safety-related outputs is galvanically separated from the other output pairs and the supply
voltage.
On the module, the outputs can be either configured as current outputs or voltage outputs.
The module has been certified by the TÜV for safety-related applications up to SIL 3
(IEC 61508, IEC 61511 and IEC 62061), Cat. 4 and PL e (EN ISO 13849-1) and SIL 4
(EN 50126, EN 50128 and EN 50129).
Further safety standards, application standards and test standards are specified in the
certificates available on the HIMA website.
3.1 Safety Function
If a module fault occurs, the affected outputs are de-energized.
3.1.1 Safety-Related Analog Outputs
To configure the analog outputs as a voltage or current outputs, each channel of the AO 8 01
module has a DIP switch with 6 functions located on the printed circuit board (PCB), next to the
front plate. The switches are arranged top-down following the the order of channels 1...8.
The switches are set individually prior to starting up the module and in accordance with the
following table:
3.1.1.1 Switch Positions
Switch
function
Output voltage
0...10 V
Output current
0...+20 mA
1 OFF ON
2 OFF ON
3 OFF ON
4 ON OFF
5 ON OFF
6 ON OFF
Table 4: Switch Positions

3 Product Description AO 8 01
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3.1.1.2 Analog Output Values
Depending on which device type (…FS1000,…FS2000) has been selected, different values
must be taken into account in the logic for the Value [INT] - > signal variable (SILworX) and for
the AO[0x].Value system signal (ELOP II Factory) to get identical output values.
Value range
in the application
Output voltage Output current
Device version FS1000
0 0.0 V 0.0 mA
+1000 +10.0 V +20.0 mA
-1000 -10.0 V 0.0 mA
Device version FS2000
0 0.0 V 0.0 mA
+2000 +10.0 V +20.0 mA
-2000 -10.0 V 0.0 mA
Table 5: Output Values of the Analog Outputs
Every two analog outputs are galvanically connected to one another (output 1 and 2, output 3
and 4, output 5 and 6, output 7 and 8).
The analog outputs are designed to retain the metrological accuracy for 10 years. A proof test
must be performed every 10 years.
3.1.1.3 Reaction in the Event of a Fault
If the module detects a discrepancy between the read back value of the output signal and the
configured value, the defective output is switched off via the safety switches.
The module activates the ERR LED.
The error code allows the user to configure additional fault reactions in the user program.
3.1.1.4 Worst Case Reaction Time
The worst case reaction time WDTAO is 12 ms.
To determine the worst case reaction time of the analog outputs, add the double watchdog time
of the AO CPU (2 * WDT AO-µC) to the double watchdog time (2 * WDT CPU), see safety manual
(HI 800 023 E).

AO 8 01 3 Product Description
HI 800 197 E Rev. 2.00 Page 13 of 38
3.2 Equipment, Scope of Delivery
The following table specifies the available component:
Designation Description
AO 8 01 Module with 8 analog outputs
Table 6: Available Component
3.3 Type Label
The type plate contains the following details:
Product name
Bar code (1D or 2D code)
Part no.
Production year
Hardware revision index (HW Rev.)
Firmware revision index (FW Rev.)
Operating voltage
Mark of conformity
Figure 1: Sample Type Label

3 Product Description AO 8 01
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3.4 Structure
This chapter describes the layout and function of the module.
3.4.1 Block Diagram
I/O Bus
A/D Microcontroller
A/D Microcontroller
Voltage/Current Switch
8 Output Channels
Figure 2: Block Diagram

AO 8 01 3 Product Description
HI 800 197 E Rev. 2.00 Page 15 of 38
3.4.2 Front View
A
O 8
01
Figure 3: Front View

3 Product Description AO 8 01
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3.4.3 Status Indicators
LED Color Status Description
On Operating voltage presentRUN Green
Off No operating voltage
On Module faulty or external faults
Reaction as dictated by the diagnosis
ERR Red
Off No module faults and / or no channel faults
Table 7: Status Indicators

AO 8 01 3 Product Description
HI 800 197 E Rev. 2.00 Page 17 of 38
3.5 Product Data
General
Operating voltage 24 VDC, -15...+20 %, rPP 15 %,
from a power supply unit with safe insulation,
in accordance with IEC 61131-2
Operating data 3.3 V / 130 mA
5 V / 280 mA
24 V / 630 mA
Ambient temperature 0...+60 °C
Storage temperature -40...+85 °C
Space requirement 6 RU, 4 HP
Weight 280 g
Table 8: Product Data
Analog outputs
Number of outputs 8 analog outputs (each two outputs are galvanically separated
from the other pairs and from the supply voltage).
Nominal range 0...10 V or
0...+20 mA
Operating range 0...10.25 V or
0...+21 mA
Output resistor 600 Ω(current operation)
> 1 kΩ(voltage operation)
Digital resolution 12-bit
Measurement accuracy at
25 °C, max.
0.3 % of final value
Metrological accuracy on full
temperature, max.
1 % of final value
Temperature coefficient, max. 0.02 %/K of final value
Safety-related accuracy, max. 1 % of final value
Table 9: Specifications for the Analog Outputs

4 Start-up AO 8 01
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4 Start-up
To start up the module, it must be mounted, connected and configured in the programming tool.
4.1 Installation and Mounting
The module is mounted in the subrack of the modular HIMatrix F60 system.
When laying cables (long cables, in particular), take appropriate measures to avoid interference,
e.g., by separating the signal lines from the power lines.
When dimensioning the cables, ensure that their electrical properties have no negative impact
on the measuring circuit.
4.1.1 Mounting and Removing the Modules
To mount and remove the modules, the connection cable clamp terminals must be unplugged.
Additionally, personnel must be protected from electrostatic discharge. For details, refer to
Chapter 2.1.2.
Mounting the Modules
To mount a module into the subrack
1. Insert the module as far as it can go – without jamming it – into the two guiding rails which
are located on the housing's upper and lower part.
2. Apply pressure to the upper and lower extremity of the front plate until the module plugs
snap into the backplane socket.
3. Secure the module with the screws located on upper and lower extremity of the front plate.
The module is mounted.
Removing the Modules
To remove a module from the subrack
1. Remove the plugs from the module front plate.
2. Release the locking screws located on the upper and lower extremity of the front plate.
3. Loosen the module using the handle located on the lower part of the front plate and remove
it from the guiding rails.
The module is removed.

AO 8 01 4 Start-up
HI 800 197 E Rev. 2.00 Page 19 of 38
4.1.2 Connecting the Analog Outputs
The outputs are connected using 9-pole connectors with numbered terminals. The terminal pins
on the front plate of the module have the same numbered sequence to avoid invalid
connections.
iEach unused analog output channels configured as current outputs, must be short-circuited to
the assigned ground.
Use the following terminals to connect the analog outputs:
Terminal Designation Function
01 O1+ Analog output 1
02 O1- Ground output 1
03 O2+ Analog output 2
04 O2- Ground output 2
05 O3+ Analog output 3
06 O3- Ground output 3
07 O4+ Analog output 4
08 O4- Ground output 4
09 Ground / shielding
Terminal Designation Function
10 O5+ Analog output 5
11 O5- Ground output 5
12 O6+ Analog output 6
13 O6- Ground output 6
14 O7+ Analog output 7
15 O7- Ground output 7
16 O8+ Analog output 8
17 O8- Ground output 8
18 Ground / shielding
Table 10: Terminal Assignment for the Analog Outputs
4.1.3 Cable Plugs
Cable plugs attached to the pin headers of the module are used to connect to the field zone.
The cable plugs are included within the scope of delivery of the HIMatrix modules.
Connection to the field zone
Number of cable plugs 2 pieces, nine poles, screw terminals
Wire cross-section 0.2…1.5 mm2 (single-wire)
0.2…1.5 mm2(finely stranded)
0.2…1.5 mm2(with wire end ferrule)
Stripping length 6 mm
Screwdriver Slotted 0.4 x 2.5 mm
Tightening torque 0.2…0.25 Nm
Table 11: Cable Plug Properties

4 Start-up AO 8 01
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4.1.4 Mounting the AO 8 01 in Zone 2
(EC Directive 94/9/EC, ATEX)
The module is suitable for mounting in zone 2. Refer to the corresponding declaration of
conformity available on the HIMA website.
When mounting the device, observe the special conditions specified in the following section.
Specific Conditions X
1. Mount the HIMatrix F60 controller in an enclosure that meets the EN 60079-15 requirements
and achieves a type of protection of at least IP54, in accordance with EN 60529. Provide the
enclosure with the following label:
Work is only permitted in the de-energized state
Exception:
If a potentially explosive atmosphere has been precluded, work can also performed when the
controller is under voltage.
2. The enclosure in use must be able to safely dissipate the generated heat. The maximum
power dissipation of the AO 8 01 module is 21 W.
3. The 24 VDCpower must come from a power supply unit with safe isolation. Use power
supply units of type PELV or SELV only.
4. Applicable standards:
VDE 0170/0171 Part 16, DIN EN 60079-15: 2004-5
VDE 0165 Part 1, DIN EN 60079-14: 1998-08
Pay particular attention to the following sections:
DIN EN 60079-15:
Chapter 5 Design
Chapter 6 Terminals and cabling
Chapter 7 Air and creeping distances
Chapter 14 Connectors
DIN EN 60079-14:
Chapter 5.2.3 Equipment for use in zone 2
Chapter 9.3 Cabling for zones 1 and 2
Chapter 12.2 Equipment for zones 1 and 2
The module is additionally equipped with the label represented below:
Figure 4: Label for Ex Conditions